The present invention relates to a connector formed by bending a large diameter electric wire which is used as a high-voltage electric wire into an L-shape, and more particularly, relates to a low height connector of which downsizing can be achieved without using a protector.
<Downsizing of a Connector>
Concerning an existing connector, it has been conducted to downsize the connector in view of necessity of a mounting space in a vehicle. In order to downsize the connector, the following two methods have been heretofore considered.
(1) Use of a protector: This is a method of providing a protector in a passage of a wire harness thereby to forcibly regulate the passage of the wire harness.
(2) Use of an L-shaped terminal: This is a method of bending a terminal of the connector into an L-shape, and forming a housing for containing the L-shaped terminal.
<(1) Use of a Protector>
An example of the connector using the protector is disclosed in JP-A-2010-211935.
The connector disclosed in JP-A-2010-211935 is a connector with an L-shaped high voltage electric wire which is formed by bending a high-voltage electric wire into an L-shape, connecting a terminal to a tip end of the high-voltage electric wire, surrounding the tip end of the high-voltage electric wire and the terminal with a housing, and then, covering the housing with a shield shell formed of aluminum. In this connector, an L-shaped bent part of the high-voltage electric wire is covered with a protector formed of resin, and further, the protector is provided with a rib thereby to give rigidity to the protector.
There are the following problems in using the protector. Firstly, components of the protectors must be provided separately for the respective passages.
Moreover, it is not easy to forcibly bend the high-voltage electric wire, because a thick wire such as the high-voltage electric wire has high resilience. Consequently, the high-voltage electric wire is bent in a large arc requiring a large space, and cannot make a low height connector.
Further, in order to forcibly regulate the passage using the protector, a thick rib for enabling the high-voltage electric wire to be bent resisting repulsion must be provided on the protector.
<(2) Use of an L-Shaped Terminal>
In
However, as a problem of this method, in case where a shape of the L-shaped terminals 30T is varied, the L-shaped terminals 30T become novel structures, and existing terminals cannot be used. In addition, the connector housing 30H for containing the terminals is also varied in shape and size, and becomes a novel structure, every time.
This invention provides a low height connector in which existing terminals can be used, without requiring a protector, and further, without requiring a large space, and a method of producing the same.
One aspect of the invention provides a method of producing a low height connector, the method comprising: removing an insulating covering from a first part of an electric wire; forming the electric wire into a predetermined shape in which the first part of the electric wire is bent; joining a terminal to a second part of the electric wire; and molding the electric wire to surround at least the first part and the second part of the electric wire with a housing to obtain the low height connector.
One aspect of the invention provides a low height connector comprising: an electric wire in which an insulating covering is removed from a first part of the electric wire, the first part of the electric wire being bent; a terminal which is joined to a second part of the electric wire; and a housing which surrounds at least the first part and the second part of the electric wire.
Referring to
<Working Steps for Producing the Mold Connector According to the Invention>
<Step 1: Preparation of a Covered Wire>
In
<Step 2: Wire Covering Peeling Step>
The insulating covering H of the wire W in
<Step 3: Wire Forming Step>
The wire W is subjected to a stamping work to be formed into an L-shape (or a Z-shape), and the wire as shown in
<Step 4: Terminal Connecting Step>
Then, an ordinary terminal T which is not bent into an L-shape is connected to the tip end W1 of the wire W, and the wire as shown in
The terminal T and the tip end W1 of the wire W, which is a twisted wire, are connected to each other by ultrasonic bonding. On this occasion, it is preferable to conduct bending work of the wire, at the same time with preforming work of the terminal T.
Moreover, a part of the insulating covering H3 to be a border with respect to a housing is surrounded with a support member S.
<Step 5: Molding Step of Housing>
A region from a part of the terminal T which is connected to the tip end W1 of the wire W up to the support member S of the insulating covering H3 is molded thereby to forma housing M, as shown in
<Connector Produced According to the Production Method of the Invention>
In
In
Because the housing is formed by extensively molding the wires which have been respectively bent, as described above, the related-art protector which has been required heretofore can be omitted. As the results, assembling steps and installations for the protector can be saved, and hence, cost reduction of the connector can be achieved. Besides, downsizing of the connector can be realized without using the protector.
Moreover, because the insulating covering is peeled off only from the parts where the wire is to be bent, the stress is exerted on rectilinear parts during the molding work, and deformation of the wire W is prevented.
Further, although a stamping die for the wire is required, constituent components of the connector and installations in the working line can be commonly used. Because the wire is subjected to the stamping work, after the covering of the wire has been peeled off, it is possible to bend the wire with a stricter R (radius), with higher accuracy as compared with the related-art wire using the protector.
Although a case where the two wires W are extensively molded with resin is shown in
<Related Art 1>
In a process to reach the invention, as Related Art 1, the inventor tried to mold a wire W having an insulating covering H, as shown in
<Related Art 2>
In a process to reach the invention, as Related Art 2, the inventor tried to peel off the whole insulating covering, as shown in
<Conclusion>
As described above, Related Art 1 and Related Art 2 have drawbacks respectively. The invention can overcome these drawbacks too, and it is possible to prevent the deformation, because the insulating covering only in the parts to be bent is peeled off, and the stress is exerted on the rectilinear parts during the molding work.
Moreover, because the housing is formed by extensively molding the wire which has been bent, as described above, the related-art protector which has been heretofore required can be omitted. As the results, the assembling steps and components for the protector can be saved, and hence, cost reduction of the connector can be achieved. Besides, downsizing of the connector can be realized without using the protector.
Moreover, the constituent components of the connector and the installations in the working line can be commonly used, although the stamping die for the wire is required. Because the wire is subjected to the stamping work, after the covering of the wire has been partially peeled off, it is possible to bend the wire with a stricter R (radius), with higher accuracy as compared with the related-art wire using the protector.
According to an aspect of the invention, it is possible to produce the low height connector in which the existing terminals can be used, without requiring a protector, and further, without requiring a large space.
Number | Date | Country | Kind |
---|---|---|---|
2011-159124 | Jul 2011 | JP | national |